Alright, I was playing around with the diff and got .008, but I'll back it off a little. The preload was so loose that you could turn the adjuster's by hand after loosening them one notch with a wrench.

I turned the adjuster wheels about halfway on the ring gear side, and about 4 notches on the pinion side.

 

Is setting up the backlash and CBPL really this easy?

 

After getting the CBPL and backlash set, I thought that before I pulled apart my truck, I'd just count the teeth to make sure it was a 4.56. I got out my pen and counted. 41 ring teeth and 10 pinion teeth... hell of a strange number for a 4.56. Phone calls have been made. Bugger.

 

OMG! Man after all that work that really sucks.

 

well s41t, thats sucks. glad you called the dude, thats a pain in the ass.

 

God, I went through the same problem, but the gear rations were the other way around. At least you got some practice?

Sure there weren't 9 pinion teeth? The 4.56 ratio is 41:9

 

Definitely 10 pinion teeth and 41 ring teeth. How annoying is that.

 

Also, it appears that in reality, a 2 pinion 4.56 is really uncommon. $250 at the wreckers, not as bad as I though, but still $100 more than I intended on spending.

 

I talked the wreckers down to $200 (from $350 originally), so I bought it.

Before
Backlash: 0.013-0.015 (after taking apart two diffs so far, this backlash appears to be the norm)
CBPL: not much

After Aussie install
Backlash: 0.009
CBPL: wheels cranked to about 100 ft-lbs

The gears don't whine and the heavier 80W140, quiets and smooths the locker a bit. The 4.56 gears are nice.

 

That sucks, but them's the breaks, I guess. Glad you caught it and got it worked out before you slapped the thing in and started wondering why your transfer case was binding up. Not a good feeling to have to pull all that stuff back apart.

Did you ever hear back from the guy you bought the other third from?

 

Yeah, he bought the third from some other guy, but went for 4.88s instead. He was very apologetic and gave me my money back right away.

I'm taking the third out again today because I STUPIDLY forgot to torque the bearing cap bolts. Hope everything is alright in there, I think it will be. I set the preload and backlash, then got called for dinner. I put the locking tab then had dinner, and came back. I completely forgot to torque the bolts to 81ft-lbs.